Valve with shuttle

ABSTRACT

A valve with a shuttle for use in a flow management system is capable of bypassing a backflow.

PRIORITY CLAIM

This application is a continuation-in-part of U.S. patent applicationSer. No. 12/766,141 filed Apr. 23, 2010 and entitled VALVE WITH SHUTTLEFOR USE IN A FLOW MANAGEMENT SYSTEM which is incorporated herein, in itsentirety and for all purposes.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a system for managing a fluid flow. Inparticular, the system includes a valve with a shuttle for managing afluid flow.

2. Discussion of the Related Art

Pumps and valves located in hard to reach places present maintenance andmaintenance downtime issues. Where pumps and valves are used to producea natural resource such as a hydrocarbon, downtime can result in lostproduction and increased expenses for workmen and materials.

In particular, downhole production strings including pumps and valvesfor lifting fluids such as particulate laden liquids and slurriespresent a maintenance problem. Here, both pumps and valves can losecapacity and in cases be rendered inoperative when conditions includingfluid conditions and fluid velocities fall outside an intended operatingrange. Such unintended operating conditions can foul, plug, and damageequipment.

Despite the industry's resistance to change, there remains a need toimprove production strings.

SUMMARY OF THE INVENTION

The present invention includes a valve with a shuttle and is intendedfor use in a flow management system.

In an embodiment, a valve body includes a spill port and a shuttle islocated in a chamber of the valve body. The shuttle has a through holeextending between a shuttle closure end and a shuttle spring end. Afirst seat and a first seat closure are located in the through hole.Second and third seats are located in the valve body chamber and secondand third seat closures are located on the shuttle closure end. A springis located substantially between the shuttle spring end and a fixturecoupled to the valve body. The valve is operable to pass a flow enteringthe through hole at the shuttle spring end and to spill a flow thatcloses the first seat closure. In some embodiments, the circumference ofthe second seat is greater than the circumference of the third seat andthe circumference of the shuttle spring end is more than two timesgreater than the circumference of the third seat.

In an embodiment, a valve body includes a spill port and a shuttlelocated in a chamber of the valve body. The shuttle has a through holeextending between a shuttle closure end and a shuttle spring end. Avalve center line is shared by the valve body and the shuttle. A firstseat is located on a first face of the shuttle and there is a first seatclosure. The first seat closure has a central bore for accepting arotatable shaft extending through the valve body and the first seatclosure is for translating along the rotatable shaft. A second seat islocated in the valve body chamber and a second seat closure is locatedon a second face of the shuttle. A spring is located substantiallybetween the shuttle spring end and a valve body support. The valve isoperable to pass a flow entering the through hole at the shuttle springend and to spill a flow that closes the first seat closure.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention is described with reference to the accompanyingfigures. These figures, incorporated herein and forming part of thespecification, illustrate the invention and, together with thedescription, further serve to explain its principles enabling a personskilled in the relevant art to make and use the invention.

FIG. 1 is a schematic diagram of a valve in a flow management system inaccordance with the present invention.

FIG. 2 is a diagram of the flow management system of FIG. 1.

FIG. 3 is a cross-sectional view of a valve of the flow managementsystem of FIG. 1.

FIG. 4 is a cross-sectional view of a second valve of the flowmanagement system of FIG. 1.

FIG. 5 is a cross-sectional view of a seal of the flow management systemof FIG. 1.

FIG. 6 is a schematic diagram of a pump-off controller implemented in atraditional production string 600.

FIG. 7 is a schematic diagram of a valve of FIG. 1 used to implement apump-off controller.

FIG. 8 is a flow chart showing a mode of operation of the valve of FIG.7.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The disclosure provided in the following pages describes examples ofsome embodiments of the invention. The designs, figures, and descriptionare non-limiting examples of certain embodiments of the invention. Forexample, other embodiments of the disclosed device may or may notinclude the features described herein. Moreover, disclosed advantagesand benefits may apply to only certain embodiments of the invention andshould not be used to limit the disclosed invention.

To the extent parts, components and functions of the described inventionexchange fluids, the associated interconnections and couplings may bedirect or indirect unless explicitly described as being limited to oneor the other. Notably, indirectly connected parts, components andfunctions may have interposed devices and/or functions known to personsof ordinary skill in the art.

FIG. 1 shows an embodiment of the invention 100 in the form of aschematic diagram. A bypass valve 108 is interconnected with a pump 104via a pump outlet 106. The pump includes a pump inlet 102 and the valveincludes a valve outlet 110 and a valve spill port 112. In variousembodiments, the inlets, outlets and ports are one or more of a fitting,flange, pipe, or similar fluid conveyance.

FIG. 2 shows a section of a typical downhole production string 200. Theproduction string includes the bypass valve 108 interposed between thepump 104 and an upper tubing string 204. In some embodiments, a casing208 surrounds one or more of the tubing string, valve, and pump. Here,an annulus 206 is formed between the tubing string and the casing. Aproduction flow is indicated by an arrow 102 while a backflow isindicated by an arrow 202. In various embodiments, the bypass valveserves to isolate backflows from one or more of the valve, portions ofthe valve, and the pump.

FIG. 3 shows a first bypass valve 300. A valve body 324 housescomponents including a valve shuttle 337 and a charge spring 312. Thevalve body has a central chamber 323.

The shuttle 337 includes an upper section 340 adjacent to a lowersection 341. In an embodiment, the central chamber includes a first bore344 for receiving the lower shuttle section and a second bore 346 forreceiving the upper shuttle section. In embodiments where the first andsecond bore diameters are different, a grease space 332 may be providedbetween the shuttle 337 and the valve body section 370 (as shown). Inother embodiments, the first and second bore diameters are substantiallythe same and there is no grease space.

Upper and lower seals 314, 330 are fitted circumferentially to the uppershuttle section and the lower shuttle section 340, 341. In anembodiment, the seals have a curved cross-section such as a circularcross-section (as shown). In another embodiment the seals have arectangular cross-section.

In some embodiments, one or more seals 314, 330 have a structure 500similar to that shown in FIG. 5. Here, a seal body 502 such as apolymeric body has inner and outer lip seals 506, 504 and substantiallyenvelops a charge O-ring 508 such as a silicon rubber ring.

In various embodiments, the seals 314, 330 are made from one or more ofa rubber, plastic, metal, or another suitable material known to personsof ordinary skill in the art. For example, seal materials includesilicone rubber, elastomers, thermoplastic elastomers, and metals thatare soft in comparison to the valve body 324, the selection depending,inter alia, on the valve application. In an embodiment, the seals aremade from ultra-high-molecular-weight polyethylene.

The shuttle has a through-hole 356 including an upper through-holesection 342 and a lower through-hole section 352. Upper and lowerthrough-hole ports 362, 360 bound a flow path through the shuttleindicated by the through-hole. In an embodiment, the upper through-holecross-section is smaller than the lower through-hole cross-section.

Located near the lower through-hole section are a first seat closure354, a first seat 326, and a seat retainer 393. In an embodiment, thefirst seat is about radially oriented with respect to the valve bodycenterline 301.

In an embodiment, the first seat closure 354 is a plug. In variousembodiments, the first seat closure is spherically shaped, conicallyshaped, elliptically shaped, or shaped in another manner known topersons of ordinary skill in the art. And, in an embodiment, the firstseat closure is substantially spherically shaped. The closure is movablewith respect to the shuttle 337 within a cage 328. When resting againstthe first seat 326, the first closure seals the lower through-hole port360. In an embodiment, a stabilizer near an upper end of the cage 351prevents the closure from blocking the passage comprising the upper andlower through-hole sections 342, 352 when the closure is near the upperend of the cage 390.

Located near an upper valve body section 350 is a second seat 318. In anembodiment, the second seat is about radially oriented with respect tothe valve body centerline 301.

A second seat closure 317 is located at an upper end of the shuttle 337.In an embodiment, the second seat closure is located on a peripheral,sloped face of the shuttle 319. In various embodiments, the second seatclosure is spherically shaped, conically shaped, elliptically shaped, orshaped in another suitable manner known to persons of ordinary skill inthe art. And, in an embodiment, the second seat closure is substantiallyfrustoconically shaped. The closure is movable with the shuttle along aline substantially parallel to a centerline of the valve body 301.

Located near the upper valve body section 350 is a third seat 368. In anembodiment, the third seat is about radially oriented with respect tothe valve body centerline 301. About radially arranged and locatedbetween the second and third seats 318, 368, are one or more spill ports316 extending between a valve body exterior 372 and the valve bodycentral chamber 323.

A third seat closure 367 is located at a shuttle 337 upper end. In anembodiment, the third seat closure is located on a peripheral, slopedface of the shuttle 319. In various embodiments, the third seat closureis spherically shaped, conically shaped, elliptically shaped, or shapedin another manner known to persons of ordinary skill in the art. And, inan embodiment, the second seat closure is substantially frustoconicallyshaped. The closure is moveable with the shuttle along a linesubstantially parallel to a centerline of the valve body 301.

The second and third seat closures 317, 367 are formed to substantiallysimultaneously close the second and third seats 318, 368. When restingagainst the second and third seats 318, 368, the second closureestablishes a flow path between a variable volume valve chamber belowthe shuttle 362 and an upper valve chamber above the second seat 364while the third closure blocks flow in the spill port 316. When movedaway from the second seat, the second closure unblocks flow in the spillport.

Tending to bias the shuttle 337 upward is the charge spring 312. Invarious embodiments, the charge spring is about radially oriented withrespect to the valve body centerline 301 and is seated 384 on an annularfixture supported by the valve body 386. In various embodiments, anupper end of the spring 382 presses against the shuttle.

In normal operation, forces on the shuttle determine the position of theshuttle.

An equilibrium position of the shuttle 337 in the valve body 324 isdetermined by the forces acting on the shuttle.

For example, when the pump 104 is lifting fluid through the valve 300,the spring constant k of the charge spring 312, the area A1, and thearea A2 are selected to cause a net upward force on the shuttle tendingto move the shuttle to its uppermost position, sealing the spill ports316. At the same time, the rising fluid lifts the first closure awayfrom its seat. These actions establish a flow path through the shuttle.In an embodiment, A1 is greater than A2. And, in an embodiment, A1 isabout three times larger than A2.

When fluid lifting stops or falls below a threshold value, the net forceon the shuttle tends to move the shuttle away from its uppermostposition. At the same time, insufficient rising fluid causes the firstclosure 354 to come to rest against the first seat 326. These actionsunblock the spill ports 316 and establish a fluid flow path from theupper chamber 364 to the spill port(s) 316 while blocking the flow paththrough the shuttle. In some embodiments, the threshold value is a flowrate specified by the pump manufacturer as being a recommended or safepump flow rate.

From the above, it can be seen insufficient fluid flow, no fluid flow,or reverse fluid flow cause the valve 300 and pump 104 to besubstantially removed from the fluid circuit and/or isolated from thefluid column above the shuttle 337. A benefit of this isolation isprotection of the valve and pump. One protection afforded is protectionfrom solids (such as sand), normally rising with the fluid but nowmoving toward the valve and pump, that might otherwise foul or block oneor both of these components. Blocking the shuttle flow path and openingthe spill ports 316 removes these solids outside the tubing string 204.

In various embodiments the valve 300 is made from metals or alloys ofmetals including one or more of steel, iron, brass, aluminum, stainlesssteel, and suitable valve seat and closure materials known to persons ofordinary skill in the art. And, in various embodiments, one or moreparts of the valve are made from non-metals. For example, valve closuresand seats may be made from one or more suitable polymers such as PTFE(Polytetrafluoroethylene), POM (Polyoxymethylene) and PEEK(Polyetheretherketone). In an embodiment, the closure 354 is made frommaterials including PEEK.

FIG. 4 shows a second bypass valve 400. A valve body 424 housescomponents including a valve shuttle 437, a valve closure 483, and acharge spring 412. The valve body has a central chamber 423 and arotatable shaft 482 passes through the central chamber. The shuttleincludes an upper section 440 adjacent to a lower section 441.

Upper and lower seals 414, 430 are fitted circumferentially to the uppershuttle section and the lower shuttle section 440, 441. In oneembodiment, the seals have a curved cross-section such as a circularcross-section. In another embodiment, the seals have a rectangularcross-section (as shown).

In some embodiments, one or more seals 414, 430 have a structure 500similar to that shown in FIG. 5. Here, a seal body 502 such as apolymeric body has inner and outer lip seals 506, 504 and substantiallyenvelops a charge O-ring 508 such as a silicon rubber ring.

And, in various embodiments, the seals 414, 430 are made from one ormore of a rubber, plastic, metal, or another suitable material known topersons of ordinary skill in the art. For example, seal materialsinclude silicone rubber, elastomers, thermoplastic elastomers, andmetals that are soft in comparison to the valve body 424, the selectiondepending, inter alia, on the valve application. In an embodiment, theseals are made from ultra-high-molecular-weight polyethylene.

The shuttle and valve closure 437, 483 have through-holes 456, 457 andthe rotatable shaft 482 passes through these through-holes. In variousembodiments, no “in/out” tools are required to insert the rotatableshaft through the shuttle and valve closure as their hole dimensionspass shafts with diameters as large as the drift of the tubing throughwhich they pass. A first face of the shuttle in the form of a first seat468 is for sealing against a face of the valve closure 467. In anembodiment, the first seat is near an upper end of the shuttle 440 andthe valve closure sealing face is near a lower end of the valve closure488. In some embodiments, the first valve seat is about radiallyoriented with respect to the valve body centerline 401. In variousembodiments, the shuttle sealing face is integral with or coupled to theshuttle. And, in various embodiments, the valve closure sealing face isintegral with or coupled to the valve closure.

A second face of the shuttle 417 is for sealing against a face of thevalve body in the form of a second seat 418. In an embodiment, thesecond seat is near an upper section of the valve body 450 and thesecond face of the shuttle is near an upper end of the shuttle 440. Insome embodiments, the second valve seat is about radially oriented withrespect to the valve body centerline 401. In various embodiments, theshuttle sealing face is integral with or coupled to the shuttle. And, invarious embodiments, the second seat is integral with or coupled to thevalve body 424.

About radially arranged and located between upper and mid valve bodysections 450, 470 are one or more spill ports 416. Each spill portextends between inner and outer walls of the valve body 471, 472.

Tending to bias the shuttle 437 upward is the charge spring 412. Invarious embodiments, the charge spring is about radially oriented withrespect to the valve body centerline 401 and is seated 413 in a slot 496formed in a valve body center section 470. In an embodiment, an upperend of the spring 415 presses against the shuttle.

During normal operation of a flow management system using the secondbypass valve 400, the shaft 482 rotates and operates the pump 104.Forces on the shuttle 437 and valve closure 483 determine theirposition. When the pump 104 is lifting fluid within the tubing andwithin a designed flow-rate range 490, the shuttle is in its uppermostposition 494 under the influence of the charging spring 412 and therising fluid lifts the valve closure free of the shuttle 484. Notably,in its uppermost position, the shuttle blocks the spill ports 416 whenshuttle sealing face 417 seals with the first seat 418. In someembodiments designed flow-rate ranges are the flow-rates specified bythe pump manufacturer as recommended and/or safe pump operating ranges.

When the pump 104 ceases to lift fluid at a sufficient rate, as withback-flow 491, the valve closure contacts the shuttle 486 and the valveclosure sealing face 467 seals with the second seat 468. Further, ifpressure P11,P22 induced forces cause the shuttle to compress the spring412, the shuttle moves downward and the spill port(s) 416 is unblockedallowing fluid in the tubing above the valve to spill outside the valve400, for example into the annular space between the tubing and thecasing 206. In various embodiments, pressure P11 acts on an annular areadefined by radii r1 and r4 while pressure P22 acts on an annular areadefined by r1 and r3. Here, the annular areas are different such as in aratio range of about 1.5-2.5 to 1 and in an embodiment in a ratio ofabout 2.0 to 1. In various embodiments, the spill port(s) is unblockedwhen the shuttle forces resulting from the pressure above the first seatP22 and the shuttle mass overcome the force of the charging spring 412and the force resulting from the pressure below the valve closure P11.

When the pump 104 ceases to lift fluid at a sufficient rate, as withback-flow 491, the valve closure contacts the shuttle 486 and the valveclosure sealing face 467 seals with the second seat 468. Further, ifpressure P11,P22 induced forces cause the shuttle to compress the spring412, the shuttle moves downward and the spill port(s) 416 is unblockedallowing fluid in the tubing above the valve to spill outside the valve400, for example into the annular space between the tubing and thecasing 206. In various embodiments, pressure P11 acts on an annular areadefined by radii r1 and r4 while pressure P22 acts on an annular areadefined by r1 and r3. Here, the annular areas are different such as in aratio range of about 1.5-2.5 to 1 and in an embodiment in a ratio ofabout 2.0 to 1. In various embodiments, the spill port(s) is unblockedwhen the shuttle forces resulting from the pressure above the first seatP22 and the shuttle mass overcome the force of the charging spring 412and the force resulting from the pressure below the valve closure P11.

From the above, it can be seen insufficient fluid flow, no fluid flow,or reverse fluid flow cause the valve 400 and pump 104 to be removedfrom the fluid circuit and/or isolated from a fluid column above theshuttle. A benefit of this isolation is protection of the valve andpump. One protection afforded is protection from solids (such as sand),normally rising with the fluid but now moving toward the valve and pump,that might otherwise foul or block one or both of these components.Blocking the flow path around the shuttle and opening the spill port(s)416 removes these solids outside the tubing string 204.

In various embodiments the valve 400 is made from metals or alloys ofmetals including one or more of steel, iron, brass, aluminum, stainlesssteel, and suitable valve seat and closure materials known to persons ofordinary skill in the art. And, in various embodiments, one or moreparts of the valve are made from non-metals. For example, valve closuresand seats may be made from one or more suitable polymers such as PTFE(Polytetrafluoroethylene), POM (Polyoxymethylene) and PEEK(Polyetheretherketone). In an embodiment, the closure 483 is made frommaterials including PEEK.

In various embodiments incorporating one or more of the featuresdescribed above, the bypass valves of FIGS. 3 and 4 providefouling/plugging protection to valves and fouling/plugging/burn-outprotection to pumps due to contaminants such as sand. For example, belowdesign production flow rates causing abnormal valve/pump operation ordamage in traditional production string equipment is avoided in manycases using embodiments of the bypass valves of the present invention.

Notably, embodiments of the bypass valves of FIGS. 3 and 4 can replaceor supplement protection systems now associated with some productionstrings. One such protection system is the “pump-off controller” (“POC”)used to protect pumps from failures due to abnormal operations such asreduced flow conditions and loss of flow conditions.

FIG. 6 shows an illustrative example of a pump off controllerinstallation in a production string 600. The portion of the productionstring 612 illustrated includes a pump 602 lifting product from areservoir 614 to the surface 616. A pump-off controller 608 receivespower from a power source 607 and provides power to the pump 610 inaccordance with a control algorithm. For example, a pressure indicatingdevice 604 monitors a pressure near the pump discharge 611 and providesa signal indicative of pressure 606 to the pump-off controller. If thepump-off controller determines the indicated pressure is below apreselected low-pressure set point, the POC stops supplying power to thepump. Conditions causing low pump discharge pressure includeinsufficient product at the pump inlet 613 (i.e. a “dry suction”), pumpfouling, and pump damage. Attempting to run the pump under any of theseconditions has the potential to damage or further damage the pump.

FIG. 7 shows a pump-off controller embodiment of the present invention700. A production string 701 includes a flow management system with apump 736 interposed between a reservoir 738 and a valve 734. Product thepump lifts from the reservoir 729 passes first through the pump and thenthrough a bypass valve 734. The bypass valve discharges 721 into atubing space 704 of a tubing string 702 that is surrounded by a casing712 creating an annulus 714 between the outer casing and the innertubing.

FIG. 8 shows a mode of bypass valve operation that substitutes for oraugments a production string pump-off controller 800. For example, aftera period of normal operation 802, the pressure differential (P111>P222)driving the flow in a production string 721 begins to fall 804. Asexplained above, low flow conditions cause the closure 354, 483 to matewith the shuttle 337, 437 which blocks flow through the valve along itscenterline 301, 401. When the forces on the shuttle 337, 437 are nolonger sufficient to maintain the shuttle in a position to block thespill port 316, 416, the shuttle moves to unblock the spill port/openthe bypass 806. During bypass operation 808, flow through the valve isblocked and the spill port(s) is open, product flows from the uppertubing string 723, enters the upper valve chamber 364, 464, and leavesthe valve through its spill port(s) 725. The spill port empties into aspace such as an annulus between the tubing and the casing 614.

Because the annulus 614 is fluidly coupled to the reservoir 738 (e.g. asshown in FIG. 7), valve bypass from the spill ports is returned to thereservoir 727 in the replenishment step 810. In various embodiments,filling the reservoir with the fluid from the valve bypass serves toflood the suction of the pump, lift the closure 354, 483, and unblockthe flow through the valve along its centerline 301, 401 where normalflow is re-established in step 812. Re-establishment of normal flow isfollowed by a return to normal operation in step 814.

The pump-off control steps of FIG. 8 result, in various embodiments, incyclic flows through the pump. The time between these cyclic flows isshorter than would occur with a traditional valve in a traditionalproduction string configuration because such strings are unable tobypass flow to the reservoir.

As persons of ordinary skill in the art will appreciate, many productionstring pumps rely on the pumped product as pump lubrication and coolant.Therefore, reducing the duration of dry pumping periods reduces pumpdamage due to operation with insufficient lubricant and coolant. Thebenefits include one or more of longer pump life, fewer outages, andhigher production from tight reservoirs.

The present invention has been disclosed in the form of exemplaryembodiments; however, it should not be limited to these embodiments.Rather, the present invention should be limited only by the claims whichfollow where the terms of the claims are given the meaning a person ofordinary skill in the art would find them to have.

1. A valve for use in a flow management system comprising: a valveincluding a body, a shuttle, and a seat closure; a rotatable shaftpassing through the body and the seat closure, the rotatable shaft foroperating a mechanical pump; and, translation of the seat closure alongthe rotatable shaft operable to mate the seat closure with a seat of theshuttle.
 2. A valve for use in a flow management system comprising: avalve including a body, a shuttle, and a seat closure; the body and seatclosure configured to receive a rotatable shaft passing therethrough,the rotatable shaft for operating a mechanical pump; the seat closureconfigured for translating along a rotatable shaft; and, the seatclosure operable to mate with a seat of the shuttle.
 3. The valve ofclaim 1 further comprising a valve bypass wherein said translation ofthe seat closure is operable to open the bypass.
 4. A method ofimplementing a substitute for a pump-off controller in a productionstring comprising the steps of: locating a pump between a reservoir anda bypass valve, the pump for pumping a reservoir product through thevalve; the valve transitioning to a bypass mode in response to a drop inflow through the valve indicating damaging pump operating conditions; inthe bypass mode, the valve interrupting the flow of the reservoirproduct through the valve; and, in the bypass mode, a bypass flowconduit conducting a bypass flow from the valve to the reservoir.
 5. Themethod of claim 4 wherein the bypass flow conduit provides fluid to anintake of the pump.
 6. The method of claim 4 wherein at least a portionof the bypass flow conduit has an annular cross-section.
 7. The methodof claim 4 wherein the valve includes a body, shuttle, and seat closure.8. The method of claim 7 further comprising the steps of: operating thepump via a rotating shaft passing through the body and the seat closure;and, the step of transitioning to a bypass mode including mating theseat closure with a seat of the shuttle.
 9. The method of claim 8further including the steps of: fluidly coupling tubing to a valveoutlet; surrounding at least a portion of the tubing with a casing tocreate at least a portion of the bypass flow conduit; and, receiving thebypass flow from the valve in the space between the casing and thetubing.
 10. A method of removing particulate from a production stringpumping path comprising the steps of: locating a pump in a productionstring flow path between a reservoir and a valve having a bypass;fluidly coupling tubing to an outlet of the valve; surrounding at leasta portion of the tubing with a casing to create an annular flow space;operating the valve bypass and removing particulate by removing at leasta portion of a particulate laden fluid column above the valve; and,receiving fluid and particulate in the annular flow space.
 11. Themethod of claim 10 wherein the step of operating the valve bypassincludes operating the bypass when a seat closure carried by a rotatablepump rod translates along the rod and mates with a seat of a shuttle andthe shuttle opens a valve spill port while compressing a spring.